How to make the air compressor more energy-saving and environmentally friendly?

Energy saving and environmentally friendly of air compressor is very important.The air compressor is the equipment with the highest energy consumption in the compressed air system, accounting for more than 90% of the total system energy consumption.

The power consumption of the air compressor is mainly related to factors such as intake pressure, exhaust temperature, air supply pressure, and exhaust volume. related. Therefore, the energy saving of air compressors is very important.

The following aspects are commonly used energy-saving and environmental protection technologies for air compressors

1.Reactive power compensation and energy saving

Air compressors usually use asynchronous motors, and the power factor of asynchronous motors is relatively low, mostly between 0.2-0.85, which varies greatly with the change of load, and the energy loss is large.

Reactive power compensation is to improve the power factor and reduce energy loss under the premise of normal operation of the motor. Installing power capacitors at the power receiving end can effectively improve the power factor, especially for low-voltage medium-sized motors that often operate continuously.

2. frequency conversion speed regulation energy saving

Frequency conversion speed regulation energy saving realizes motor speed regulation by installing a frequency converter between the grid and the motor to change the voltage and motor frequency. The speed of the air compressor is controlled by the frequency converter to adjust the energy to meet the needs of light-load operation and match the exhaust volume with the air consumption.

Practice has proved that the use of frequency conversion speed regulation method can improve the working efficiency of the air compressor under light-load operation, reduce the energy consumption of the air compressor, and create better economic benefits for the enterprise.

The system controls the output pressure, connects the feedback signal to the frequency converter, and compares it with the given signal. After PID adjustment, the integrated signal is sent to the input given end, and the speed and power of the motor are adjusted according to the pressure variation.

3.Multi-unit group control energy saving

In the occasions where the air consumption is large and the air load fluctuates greatly, it is difficult to use a single large-capacity air compressor to meet the needs of air volume adjustment, and multiple air compressors are often used. Multi-unit group control technology is one of the effective ways to realize energy saving under the condition of multiple air compressors operating.

It selects the required machines and the number of units according to the actual air consumption, eliminates unnecessary waste, and has a significant energy-saving effect. The screw machine can reduce the unloading running time of the equipment through the group control system, and the air compressor system adjusts the air supply pressure according to the actual pressure demand of the air end, which can achieve a better energy-saving effect.

4.Waste heat recovery technology saves energy

During the air compression process, more than 90% of the electrical energy is converted into heat and dissipated. In engineering, the recyclable heat energy is not less than 70% of the power consumption of the air compressor, and the energy recovered from waste heat is considerable. The recovered heat can be used for domestic heat, boiler feed water preheating, process heating, heating heat and other occasions. Waste heat recovery can reduce the exhaust temperature of the air compressor, prolong the service life of the air compressor, prolong the service life of the cooling oil and many other advantages. It is widely used in energy-saving projects.

5.Energy-saving technical methods to improve the operation of air compressors

• Equipped with high-efficiency motor

High-power motors seriously affect the energy-saving performance of the air compressor. The load rate of the motor of the air compressor is kept above 80%, which can improve the energy-saving efficiency. Therefore, it is essential to give priority to high-efficiency motors and reduce the floating capacity of the motors. is also imperative. The power consumption efficiency of the Y-type stepper motor is 0.5% lower than that of the general JO-type motor, and the average efficiency of the YX-type motor is 10%, which is 3% higher than that of the JO-type motor. In addition, the use of magnetic materials with low energy consumption and good magnetic permeability can reduce the consumption of copper, iron and other materials.

• Improve the transmission efficiency of the air compressor

High processing precision, good quality tapes and pulleys can effectively improve the transmission efficiency of the V-belt. Once the tightness of the V-belt is found to be inconsistent, it should be replaced immediately, not in batches, so as to avoid the load on the V-belt. Unevenness occurs; in order to ensure the required wrap angle and transmission tension of the transmission belt, the center distance of the transmission belt must be adjusted and the installation level must be improved.

Ordinary old-fashioned (V-belt drive and gear drive) transmission methods will lose more transmission efficiency and reduce energy-saving performance. Nowadays, the emergence of the motor coaxial and rotor structure can completely solve the energy loss caused by the mechanical transmission mode, increase the air volume, and control the speed of the equipment within a full range.

• Reduce frictional power consumption

The internal structure of the volumetric air compressor mainly realizes the transmission of air pressure through the movement of the piston. There is a certain friction between the movement of the piston. The size of the gap between the piston and the cylinder wall and the lubrication condition directly affect the performance of the air compressor. Efficiency play.

To ensure a good lubrication effect between the cylinder and the piston, there are mainly the following points: control the gap between the cylinder and the piston through fine debugging, and ensure that the piston ring is intact through maintenance; check the lubricating oil in time use clean lubricating oil; check the capacity of lubricating oil to ensure smooth oil circulation and timely heat dissipation; use high-quality lubricating oil to reduce power consumption caused by friction; carry out regular maintenance and Maintenance to make it work in good condition; regular replacement of lubricating oil.

• Reduce the pressure loss and leakage of the air compressor

The air circuit system of the air compressor is one of the main systems to ensure the normal operation and safety of the air compressor. It is generally composed of suction and exhaust valves, air filters, sealing gas devices and other components. A huge amount of energy is generated inside the compressor. Reasonable use of gas energy can effectively optimize energy-saving technology and reduce the energy consumption of the air compressor.

Therefore, in the manufacturing process of the air compressor, the use of advanced decompression components can be achieved by reducing the resistance of the system air flow, increasing the inner diameter of the air flow tube, enhancing the air pressure inside the air compressor, and reducing the number of gas delivery pipes.

The surrounding design avoids the reduction of pressure during the gas delivery process. In addition, aiming at the disadvantages of repeated compression of traditional air compressors, the use efficiency of the air compressor is increased by reducing the internal and external leakage volume, and the actual production process is reduced. Reduce the energy consumption caused by repeated compression operations, expand the energy-saving effect, and realize green production and operation.

Factors such as equipment and operation management all affect the energy consumption of the air compressor. Only by comprehensive analysis and comprehensive consideration, and the selection of advanced technology, reasonable and feasible methods and supporting measures, can the energy-saving, stable and safe operation of the air compressor be ensured.

While applying advanced technologies and methods such as frequency conversion and speed regulation, the staff should conscientiously do a good job in the daily operation management and maintenance of the equipment, save energy and reduce consumption on the basis of ensuring production, so as to improve economic and social benefits.

Sollant Focus on Energy Saving.

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